I'm in the process of putting back on the road a 2003 A2 (1.6 FSI), which I bought on a whim sight unseen with a cooling system failure (exploded aftermarket pipe-of-death, hopefully minimal use without coolant,then I also changed the F265 thermostat and G294 MAP sensor, fixed some other leaks and a number of other irritating issues, some still pending).
One annoying item was a broken fuel flap switch 8Z1959833 5PR as well as the locking actuator tip 8Z0862167 (I suppose the switch first from fatigue of the range limiting straps, then the rod by use of force at the station rather than manually actuating it via the trunk...).
I found the actuator tip being the same as that on Audi Q7 4L0810773A which I sourced used to get the tip, and opted to adapt a similar shaped Golf4 switch (3B0959833A like). The plastic shape of the VW switch had to be trimmed a little on the back with an xacto knife so that it would rest flat on the plastic B-pillar trim (vs. Directly on metal I suppose, which would be thinner) then it fits well enough even if flat rather than curved like the original.
I got a pigtail with it to ease with the wiring and make the swap easilly reversible by soldering a little pin at the end of the 3 useful wires to plug into the female socket of the Audi A2 harness where the Audi switch used to be.
The momentary switching is expected between contacts 1 and 4 on the Audi side, and one should pay attention to polarity if the door opened red LED is expected to lit as intended (powered via Audi contact 3), so the wiring was done like this:
AudiA2 Audi wire colors VW Golf4 VW wire colors
1 red/white 3(3) red/yellow thick
3 red/blue 1(02) blue/grey thin
4 brown/yellow 2(11) blue/red thick
4(60) left hanging brown
one problem fixed, quite a few more to go...
One annoying item was a broken fuel flap switch 8Z1959833 5PR as well as the locking actuator tip 8Z0862167 (I suppose the switch first from fatigue of the range limiting straps, then the rod by use of force at the station rather than manually actuating it via the trunk...).
I found the actuator tip being the same as that on Audi Q7 4L0810773A which I sourced used to get the tip, and opted to adapt a similar shaped Golf4 switch (3B0959833A like). The plastic shape of the VW switch had to be trimmed a little on the back with an xacto knife so that it would rest flat on the plastic B-pillar trim (vs. Directly on metal I suppose, which would be thinner) then it fits well enough even if flat rather than curved like the original.
I got a pigtail with it to ease with the wiring and make the swap easilly reversible by soldering a little pin at the end of the 3 useful wires to plug into the female socket of the Audi A2 harness where the Audi switch used to be.
The momentary switching is expected between contacts 1 and 4 on the Audi side, and one should pay attention to polarity if the door opened red LED is expected to lit as intended (powered via Audi contact 3), so the wiring was done like this:
AudiA2 Audi wire colors VW Golf4 VW wire colors
1 red/white 3(3) red/yellow thick
3 red/blue 1(02) blue/grey thin
4 brown/yellow 2(11) blue/red thick
4(60) left hanging brown
one problem fixed, quite a few more to go...
